Lower Engine Disassembly; Crankcase Disassembly And Inspection; Starter Drive Gears Removal And Inspection; Flywheel / One-Way Starter Clutch Removal And Inspection - Polaris Outlaw 500 Service Manual

LOWER ENGINE DISASSEMBLY

Crankcase Disassembly and Inspection

NOTE: The starter motor, starter drive gears,
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame.
NOTE: Crankcase and transmission components
cannot be serviced in the frame. Upper engine
components, with the exception of the starter and
stator removal, must be disassembled prior to
performing these procedures.

Starter Drive Gears Removal and Inspection

1. Remove the starter.
2. Remove the 12 bolts holding the stator cover assembly.
3. Inspect the drive gears and shafts for wear or damage and
replace if necessary.
4. Measure the OD of the starter drive shafts on both ends and
record. Measure in two directions 90° apart to determine if
components are out of round. Replace if components are
worn or damaged.
5. Measure the ID of the bushing in the stator housing (A) and
the crankcase and record. Measure in two directions 90°
apart to determine if cover is out of round. Replace cover
if clearance is determined to be excessive.
A
6. Inspect gear teeth on starter drive gears. Replace gears if
gear teeth are cracked, worn, or broken.
7. Installation: Reverse the removal procedures and install
with a new gasket. Do not use sealant. Torque the bolts in
a criss-cross pattern to 80–97 in. lbs. (9–11 Nm).
Flywheel / One-Way Starter Clutch
Removal and Inspection
1. Remove flywheel nut and washer.
2. Install Flywheel Puller (PA-46075) and remove flywheel.
IMPORTANT: Thread the puller onto the flywheel fully
or flywheel threads may be damaged.
ENGINE
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